Volkswagen TRANSPORTER 1963 User manual

VOLKSWAGEN
TRANSPORTER
INSTRUCTION MANUAL
November 1963 Edition
VOLKSWAGENWERK AG WOLFSBURG
Germany

2
CONTENTS
Controls and instruments
Operating instructions
Practical driving
Cold weather hints
Lubrication
Care of tires
Care of vehicle
Maintenance
General description
Technical Data
Bulb chart
Lubrication chart
Maintenance chart
Index
Tools and accessories
3
7
21
26
29
38
40
44
63
67
73
75
76
77
inside back cover
If you want to learn the most important information about
your Volkswagen Transporter quickly, please read the first
three sections:
Controls and instruments
Operating instructions
Practical driving
Page 3
Page 7
Page 21
This manual is valid for the 1200and 1500Transporter .
All 1500Transporter technical detail which differs is
printed in blue.
1

CONTROLS AND INSTRUMENTS
The first thing you must do is become familiar with the controls and instru-
ments of your new VW Transporter. Sit behind the wheel, make yourself
comfortable, and get acquainted with all the various levers, switches and
controls. Some of the features you may already know. Check your present
knowledge against this complete list.
1 THE VEHICLE KEYS
Only one key is required for the locks in the vehicle doors and rear panel and
to operate the starter-ignition lock (29). If your vehicle is equipped with a
steering-ignition lock you will receive a second key. It is advisable to make
a note of the key number and keep it with the vehicle documents. If a key is
lost, you can then quote the number when ordering a replacement from
your VW Dealer .
INSTRUMENTS :
1- Fuel gauge
2- Warning light - Red - Generator and cooling
3- Speedometer and mileage recorder
4- Warning light- Green - Flashing indicators
5- Warning light- Blue - Headlight high beam
6- Warning light - Green - Oil pressure
3

7 - Switch for cab lighting
8 -Fresh air distributor
9- Fresh air regulator lever
10- Steering wheel
11- Horn button
12- Lighting switch and instrument light control
13- Windshield wiper switch
14- Turn indicator switch
15- Switch for load compartment light
16- Gear lever
17- Warm air control
18- Hand brake
19- Square key
20- Accelerator
21- Brake pedal
22- Clutch pedal
23- Dimmer switch
24- Heating control knob
25- Door window fastener
26- Inside door handle
27- Vent wing lock button
28- Vent wing fastener
29- Ignition /starter switch
5

r
6
Among the papers which come with your vehicle you will find details re-
garding the model, year of construction, and chassis and engine numben,.
The Police or Traffic Department may check whether or not the information
on the papers corresponds exactly with that on your vehicle.
THE CHASSIS NUMBER
is stamped on the engine cover
plate near the battery.
THE IDENTIFICATION
PLATE
,s on the right hand side of the
air duct in the cab.
THE ENGINE NUMBER
is on the crankcase flange for
the generator support.

-i ii~
u~ o-
OPERATING INSTRUCTIONS
BEFORE YOU DRIVE AWAY
please check
• engine oil level
• fan belt tension
• quantity of fuel in the tank
• tire pressures
• efficiency of brakes
• position of rear view mirror
and, if driving at night
or in foggy weather,
• the exterior lights
7

The engine compartment lid is opened with the square key which is located
in a holder in the cab near the left headlamp housing. T he lid can be lowered
by pressing against the horizontal bar of the check mechanism.
8
ENGINE OIL LEVEL
The oil level can only be checked with
the engine at rest. The oil level is satis-
factory when it is between the two
marks on the oil level dipstick, but
it should never be permitted to drop
below the lower mark. To make an
accurate check, it is best to wipe the
dipstick with a clean rag beforehand.
Should it become necessary to top up,
please remember the following hints:
Most oils marketed at present contain
chemical ingredients to improve their
lubricating qualities. However, oils of

different origin behave differently when used as engine lubricants and
should, therefore, not be mixed.
Select an HD oil of a well-known and dependable brand right at the
beginning and stick to it.
Further hints regarding engine oil changes are given in the sections "Cold
Weather Hints" and "lubrication" on pages 28 and 30-33.
FAN BELT
The V-belt drives the generator and the fan. Perfect condition and correct
tension ensures long belt life and adequate engine cooling. Checking
is very simple: when pressed with the finger, the belt must yield approxi-
mately 15mm . (.6 "). If you find any sign of wear, such as frayed edges,
see your VW Dealer. Although the belt has a long service life, always carry
a spare on the vehicle. Details are given on page 46.
a= 15 mm. (.6")
FUEL TANK
The tank has a capacity of 40 liters (10.6 U.S. gals., 8.8 Imp. gals.), which is
sufficient for a distance of about 400kilometers (250miles).
The tank filler neck on the right-hand side of the vehicle is accessible after
opening the cover with the square key delivered with the vehicle.
9
•

The fuel gauge shows the amount of fuel in the tank. When the needle is on
"R" (Reserve) it is time to refuel at the next opportunity. The5 liters remain-
ing in the tank will last for about 50km. (30 miles).
The choice of fuel type and brand is left entirely to you. The VW engine is so
designed that it will run satisfactorily on all normal reputable fuels. All good
brands, includ ing regular and premium mixtures, are distingu ished by their
consistent composition adequate anti-knock properties and freedom from
harmful ingredients.
THE TIR ES
deserve and require your particular attention. A special section deals with
the care of the tires on pages 39--40. The riding comfort and the road holding
of your Transporter will greatly depend on their condition. Maintaining cor-
rect tire pressure and avoiding driving abuses are the most important factors
in obtaining maximum tire life. Check regularly and keep tires inflated to
the following pressures:
10
l!I

Rear:
Up to 1/ . payload 2.3kg. cm•. (33psi.)
With full load .. 2.5kg, 1cm•. (36 psi.)
Spare wheel .. 2.5 kg.fem•.
Front 2.0kg.'cm•. (28psi.)
Ambul ance
Front and Rear 1.8 kg./cm•.
(26 psi. )
The tire pressures on the 1Ton Trans-
porter are as follows:
Front . . .. . . . 2.0kg. cm2• (28 psi).
Rear:
Upto 3 4 payload 2.3kg. cm•. (33 psi.)
With full load . 2.8kg. cm•. (40psi.)
Spare wheel 2.8kg. cm•. (40psi.)
Do not forget to replace the valve dust
caps.
THE BRAKES
should be checked while the vehicle is in motion before starting out on a trip
to make sure they are in good working order. The section "Apply the Brakes
Gently" on page 17deals with the correct application of brakes under various
circumstances .
GOOD EXTERIOR LIGHTS
are the first requirement of safe night driving. The three positions of the
light switch are the following:
Fully pushed in - Off.
Pulled out to first stop - Parking light, tail and license plate lights.
Fully pulled out - Headlight high or low beams (depending on
position of foot dimmer switch), tail and
license plate lights.
When the lighting switch knob is pulled out to either the first or second stop,
the instrument light is automatically turned on. By turning the knob a variable
degree of instrument lighting is obtained; turning the knob to extreme left
turns out the light entirely. When checking the lighting system, do not for-
get the two stop lights which shou ld light up when depressing the brake
pedal with the ignition turned on.
11

STARTING THE ENGINE
The ignition and starter are switched on, one after the other, by means of the
combined starter-ignition switch. As starter operation stresses the battery
heavily, other big current users, such as the headlights windshield wiper and
radio, should not be switched on when starting. Make sure, also, that the
gear shift lever is in neutral.
First switch on the ignition by turning the key to the right unti l the red and
green warning lights in the speedometer come on. Then operate the starter
without delay by turning the key further to the right.
At temperatures above freezing point or when the engine is still warm,
depress the accelerator pedal slightly while operating the starter. Only
when the engine is very warm should the accelerator be fully depressed.
At temperatures below freezing point and when the engine is cold, de-
press the accelerator pedal fully and then release it before switching on the
ignition. This enables the automatic choke device to close the choke valve. As
the engine and transmission oils tend to become thick when cold, you should
12

also declutch when starting so that the starter motor only has to turn the
engine. As soon as the engine starts, release the ignition key so that th e
starter is switched off. You can then drive off straight away as the choke
valve opens automatically as the engine warms up and regulates the idling
speed to suit the engine temperature . Do not race the engine whe n it is
completely cold. If the engine does not start within the first 10 seconds,
pause for about the same length of time to rest the battery before repeating
the starter operation. The ignition will have to be switched off firs t and then
on again as a non-repeat lock in the switch prevents the starter from being
operated repeatedly when the ignition is on and thus being damaged by the
engine when it is running. The starting procedure should not be interrupted
if the engine is heard to fire a few times without start ing.
If your vehicle has a steering-ignition lock, the engine is started in the same
manner.
Caution
Becareful when starting the engine inside your garage. Keep the door
and windows open so that the exhaust fume s can escape. These con-
tain deadly carbon monoxide which is a colorless, tasteless and odor-
less gas.
MOVING OFF
is extremely easy, if you observe the following:
1-Depress the clutch pedal as far as possible. Keep it in that position.
2- Shift to the first gear. Release the hand brake.
3 -Engage the clutch by allowing the pedal to return slowly, and
simultaneously depress the accelerator pedal. The vehicle will
start to move forward.
4-Gradually increase the pressure on the accelerator pedal and re-
move your foot completely from the clutch pedal, as the clutch is
now fully engaged.
13

Shifting to second gear is equally
simp le:
1- Take your foot off the accel era-
tor pedal, simultaneously de-
pressing the clutch pedal.
2 - Shift gear lever into second
position.
3 - Engage the clutch gently by
gradually taking your foot off
the pedal , and at th e same
time depressing the accelerat or
pedal .
You now know how to "shift gears", and may at will shift to third and fourth
positions. A s you have noticed the accelerator and clutch pedals are operated
simu ltaneous ly, but in opposite directions. It is the coordination of these
operations that brings skill in shifting gears.
THE REVERSE GEAR
should never be engaged unless the vehicle is at a standstill .To engage the
reverse gear, first press down the gear lever vertically, move it to the left and
pul l it rearwards.
SHIFTING TO A LOWER GEAR
This is what you should do in dense city traffic, or with sharp turns aheadof
you, or when driv ing up-hill.
1 -Release accelerator pedal and depress clutch pedal .
2 -Shift to 3rd, 2nd or 1st gear respectively.
3 -Release clutch pedal and depress accelerator pedal simul-
taneously.
Of course, this takes less time to do than it does to describe. We do not want
to bore you with a technical discourse, but it may be of interest to you to
know that, when shifting down, the synchromesh device ensures meshing
of the gears without clash, as the lower gear is synchronized so that both
gears are turning at the same speed.
14

To ensure correct synchromesh operation, it is essential that the clutch is
fully disengaged when shifting gears. If the clutch pedal is only partia lly
depressed, the gears will be difficu lt to engage and the synchromesh units
will wear prematurely.
To avoid undue strain on transmission and engine, shifti ng down shou ld
only be effected within the speed range of the lower gear i.e.
1200T ransporter
from 4th into 3rd gear between 65
and 30 kph (40 and 20 mph) and
from 3rd into 2nd gear between
40 and 20 kph (25 and 12 mph).
1500Tran sporter
between 75 and 30 kph (40 and
20 mph)
between 45 and 20 kph (27 and
12mph)
The 1st gear is only used for moving off, driving at walking pace, or on very
steep inclines.
After a short period of practice, you will take pleasure in shifting the gears
properly and obtain the utmost satisfaction from the efficient performance of
your new Transporter. Under no circumstances should you be afraid to
shift to a lower gear, or even try to avoid shifting occasionally by merely
"slipping" (partly disengaging) the clutch.
Do not use clutch pedal as a foot-re st while driving you r vehicle.
APPLY THE BRAKES GENTLY
The brake responds to even the slightest foot pressure. Increasing the pres-
sure will slow the vehicle down progressively. However, avoid locking the
wheels. Locked wheels will not shorten the braking distance but may cause
you to lose control over the movement of the vehicle and will affect the tires
adversely.
Here are a few rules on braking:
Use your brakes befor e, not while making a turn.
It is neither practica l nor economical to shift to a lower gear far ahead of a
turn. Do not hesitate to use the brakes and to shift shortly before entering a
curve so that you may accelerate while still negotiating it.
To jam on the brakes suddenly can only be justified when danger is ahead.
Nevertheless, it is advisable to check the full braking efficiency from time to
time to familiarize yourself with the reaction of the vehicle and with the actua l
stopping distance. Never forget to look in the rear view mirror to make sure
15

that you will not endanger any vehicle that might be following you. Opera!
your brakes especially gently when the road is wet or covered with ice a
locked wheels will result in skidding.
When driving downhill, make use of the braking capacity of the engine com-
pression by shifting to the gear which you would use in driving up-hill. You
will attain a higher degree of safety and at the same time you will save and
preserve the brakes if you use them only to control the speed occasionally
The ignition must never be switched off when going downhill.
STOPPING THE VEHICLE
Take your foot off the accelerator pedal and apply the brakes gently. Shortly
before the vehicle comes to a full stop, depress the clutch pedal and place
the gear lever in neutral. The engine continues to idle.
If you wish to switch off the engine, merely turn the ignition key to the left.
On vehicles with the steering-ignition lock, it is important to remember not
to withdraw the ignition key until the vehicle is stationary as the steering is
locked when the key is in the "Haft" position.
MISTED WINDOWS
will greatly reduce visibility. This is brought about by the humidity from the
passengers' breath in the car and a low outside temperature. By using the
vent windows intelligently sufficient fresh air can be provided while the used
air is sucked out. Not only will the windows remain clear but so will your
head.
THE CAB SEATS
are divided into an adjustable driver's seat and a seat bench. The driver's
seat can be adjusted longitudinally, even when the vehicle is in motion, by
lifting the adjusting lever and sliding the seat forward or backward until the
best position is obtained. After adjusting, ensure that the lever engages
properly so that the seat does not slide unintentionally while driving.
The angle of the back rest can be altered by turning the two adjusting
screws.
The seat bench can be tipped forward and taken out easily.
16

A-Ad1usting screws
Sitting and driving for long periods places a certain amount of strain on the
human body. It is, therefore, important to adjust the seat correctly to your
individual requirements, and so avoid unnecessary fatigue.
THE REAR VIEW MIRROR
can be adjusted from the driver's seat to suit individual requirements. Set
it so that you can see the entire width of the road behind the vehicle for a
great distance without turning the head or the upper part of the body.
THE SUN VISORS
canbe swivelled towards the door windows to give protection against dazzle
from the side.
THE INTERIOR LIGHT
of the cab is operated by a
switch built into the lamp .
The light in the loading com-
partmentor passenger compart-
ment is operated by the tumbler
switch situated on the left hand
side of the inst rument panel
below the speedometer.
17

THE WINDSHI ELD WIPERS
operate when the knob on the left of the speedometer is pulled out.
The wiper blades should be removed occasionally and cleaned thorough
with a hard brush and methylated spirits or a strong detergent solution. Pa
cularly during long dry periods they tend to become clogged with tar splas
es and insects. The blades should be renewed once a year.
VENTILATION
Of the cab and loading compartment takes place via a duct on the roof pan
when the vehicle is moving. The amount of air admitted can be regulated
moving the lever on the left side of the duct to one of three positions. InI
rear position the duct is closed completely.
a - Fresh air
regulator
lever
1 - On
2- Off
b - Fresh air
distributio
1 - Cab
2 - Loadin
compa
men!or
passen
compa
ment
The fresh air can be distributed to cab or loading compartment by means
the lever below the duct. When set across the duct, the air is directed to
cab and when set lengthwise the loading or passenger compartment
ventilated. When the lever is set between the end positions, air is directed
both parts.
18

THE SUN ROOF
is free to slide when the locking lever is turned to the left. It may be fixed in
any desired position by merely twisting the lever to the right. It is good prac-
tice, however, to open the roof fully prior to sliding it to the desired position.
This will not only make the opened roof look better, but will also fold the
material properly.
To close the sliding roof, turn the handle to the left first, then pull the roof
forwards until the locking hook engages and turn handle to the right.
If you havea Pick-up, note the following: When the tarpaulin is wet from rain
or washing, always let it dry on the vehicle to avoid shrinkage.
SLIDING DOOR
If your Transporter has a sliding door instead of the normal wing doo r,
note the following instructions:
To open the door, press the handle down. The door slides back easily and
is held open by a lever.
19